Pliable ground calcium carbonates storage articles and method of making same

ABSTRACT

The present invention is directed to a storage article, such as a retail and/or shipping package, having an environmentally friendly pliable composite structure that has a high degree of pliability and flexibility and is highly attractive in look and feel. The pliable composite structure has a base layer and a ground calcium carbonate-containing layer covering the base layer. The base layer and ground calcium carbonate-containing layer are shaped, sized and manufactured such that the pliable composite structure formed therefrom is sufficiently pliable and flexible to form the storage article.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No.60/956,690, filed Aug. 18, 2007, which is hereby incorporated byreference in its entirety.

STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT

Not Applicable

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates generally to storage articles such asretail and/or shipping product packages having a pliable ground calciumcarbonate-containing material that is highly attractive, efficient tomanufacture, and environmentally friendly.

2. Related Art

Packages and packaging material for product retail and shipping purposesare typically designed to be sufficiently durable to allow reliable useof the materials. Considerations that are taken into account in thedevelopment of such packages and materials include their resistance toheat, fire and moisture, as well as resistance to infiltration byrodents and pests, and the ability of the packages and materials todeter theft. The packages and packaging materials are also desirablyrelatively inexpensive to manufacture, and are preferably attractiveenough to the customer in appearance, feel and touch to encourage use ofthe products as well as to enhance the product image or association.

However, it can be difficult to create packaging products that are bothattractive to consumers and inexpensive to fabricate while also beingsufficiently durable to meet the needs of retail and shipping use. Forexample, some lower cost packaging options are poorly configured toprevent theft because of minimal investment in protective structures.Examples of packages that may not be as great of a theft deterrent arecommon blister packages, and shrink-wrapped or flexible film stylepackaging. While clamshell style packaging is an example of more theftresistant packaging due to the typically higher gauge materials usedtherein, the packaging is also typically more expensive due to the useof the higher cost materials.

A further problem that exists with prior packaging products is thatthese products may not incorporate environmentally friendly materialsand designs. Environmentally friendly materials can have desirableattributes such as biodegradability, compostability, a high recycledcontent, and may also use less energy, pollute less, and generate fewergreenhouse gases in their manufacture than previous materials. Suchenvironmentally friendly materials are increasingly in demand fromconsumers and retailers, and can be beneficial for manufacturers byreducing adverse environmental impact of the material.

An example of an environmentally friendly material is ground calciumcarbonate (GCC), which is a material that can be combined with bondingagents and extruded to form material layers. Environmentally friendlyground calcium carbonate extrusion materials include materials similarto ones with the tradename Via-Stone™ that is manufactured by TaiwanLung Meng Corporation, which is incorporated into a synthetic commercialprinting paper. The ground calcium carbonate material can be fabricatedfrom natural sources, such as limestone, and can be biodegradable, andthus represents an advantage over other non-biodegradable and lessenvironmentally friendly materials.

FIGS. 1 a through 1 c show a blister card package 10 that incorporatesan environmentally friendly ground calcium carbonate material in anon-composite form, and that is commercially available from One SourceIndustries in Irvine, Calif. The blister card package 10 is formed byadhering a front card portion 12 a to a back card portion 12 b, with thefront card portion 12 a having a cutout sized to fit a plastic “blister”14 therethrough in which the retail product 16 is contained anddisplayed. The blister 14 has flanges 18 that are sealed in between thetwo card portions 12 a and 12 b to form a sturdy blister card package10. In this embodiment, a front card portion 12 a may be fabricated of acard of ground calcium carbonate containing material, and the back cardportion 12 b can be formed of a rigid paperboard card. The front andback card portions 12 a, 12 b can then be heat sealed together to jointhe cards in a limited surface area that is dictated by the heat sealingpattern at the interface between the two card portions 12 a, 12 b,thereby trapping the blister between the two card portions 12 a, 12 b.Adhesive or glue can also be applied at various regions of the interfacebetween the front and back card portions, such as about the blisterflanges 18 or about a periphery of the cards. The typically rigid cardmaterials used for the back and/or front card portions 12 a, 12 b, anduse of adhesive or other agents in the adhesion of the card portions 12a, 12 b forms a rigid and stiff overall card package, which has theadvantages of imparting theft and tear resistance to the blister cardpackage. The ground calcium carbonate-containing material also impartsan attractive look to the blister card package, with the ground calciumcarbonate material having the added advantage that it is environmentallyfriendly, and renders the package readily printable with advertising orproduct information.

However, a problem with such blister card products is that they aretypically not as attractive to consumers in terms of look, feel andtouch, as other less environmentally sound products, due to the rigidityand tactile unpleasantness of the stiff packaging. Also, some large clubstores require that packages have designs with sufficient externalstrength to allow for vertical and other stacking of the packages inpallet pack layers, which can be difficult to achieve when incorporatinga plastic “blister” portion into the packaging. The blister packagingalso may not provide the best theft deterrence.

Accordingly, there remains a need in the art for retail and/or shippingpackages that are durable and cost effective while also being attractiveto consumers in terms of appearance and touch. There is also a need forretail and/or shipping packages that are durable and attractive whileincorporating environmentally friendly materials and being resistant totheft.

BRIEF SUMMARY OF THE INVENTION

The present invention specifically addresses and alleviates theabove-identified deficiencies in the art. In this regard, the presentinvention is directed to an environmentally friendly storage article(e.g., a retail and/or shipping package) having a pliable compositestructure that has a high degree of pliability and flexibility. Thepliable composite structure has a base layer and a ground calciumcarbonate-containing layer covering the base layer. The base layer andground calcium carbonate-containing layer are shaped, sized andmanufactured such that the pliable composite structure formed therefromis sufficiently pliable and flexible to form the storage article. Thepliable composite structure can be formed by adhering the calciumcarbonate-containing layer to the base layer, and shaping the pliablecomposite structure into a desired component form. The pliable compositestructure can be used in the fabrication of packages that are highlyattractive in look and feel, while also having high durability.

In one version, the pliable composite structure is formed into the shapeof a box for retail and/or shipping purposes. The pliable compositestructure may also be formed into the shape of a container liner, ashipping mailer, a display or display tray, slip or tear sheets, palletcovers, corrugated structures and interior protective packagingcomponents, and other retail and/or shipping components.

The present invention is best understood by reference to the followingdetailed description when read in conjunction with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These as well as other features of the present invention will becomemore apparent upon reference to the drawings wherein:

FIG. 1 a is a schematic side view of a prior art blister card packageshowing a product held in a blister that is sandwiched between top andbottom card portions;

FIG. 1 b is a schematic side view of the prior art blister card packageof FIG. 1 a having the top and bottom card portions sealed to oneanother;

FIG. 1 c is a schematic front view of the prior art blister card packageof FIGS. 1 a-1 b showing the product displayed within the blisterportion of the package;

FIG. 2 is a side view of a pliable composite structure having a baselayer and a ground calcium carbonate-containing layer covering the baselayer;

FIGS. 3 a-3 b are side views of embodiments of pliable compositestructures formed into the shape of at least one of a shipping box andretail box;

FIGS. 4 a-4 b are side views of embodiments of containers having pliablecomposite structures formed into the shape of container liners;

FIG. 5 is a front view of a shipping mailer having the pliable compositestructure;

FIGS. 6 a-6 g are front views of embodiments of retail displays anddisplay trays having the pliable composite structure;

FIG. 7 a is a sectional side view of a corrugated structure having thepliable composite structure;

FIG. 7 b is a sectional top view of the corrugated structure having thepliable composite structure of FIG. 7 a;

FIG. 8 is top view of a tear sheet or slip sheet having the pliablecomposite structure which may optionally be used as a pallet cover;

FIG. 9 is a sectional side view of an interior protective packagingcomponent having the pliable composite structure and containing shockabsorbing material;

FIG. 10 is a sectional side view of an interior protective packagingcomponent having the pliable composite structure molded onto a shockabsorbing material; and

FIG. 11 is a schematic side view of a vacuum-forming apparatus suitablefor molding pliable composite structures into shapes for storagearticles.

Common reference numerals are used throughout the drawings and detaileddescription to indicate like elements.

DETAILED DESCRIPTION OF THE INVENTION

The detailed description set forth below is intended as a description ofthe presently preferred embodiment of the invention, and is not intendedto represent the only form in which the present invention may beconstructed or utilized. The description sets forth the functions andsequences of steps for constructing and operating the invention. It isto be understood, however, that the same or equivalent functions andsequences may be accomplished by different embodiments and that they arealso intended to be encompassed within the scope of the invention.

It has been discovered that environmentally friendly and attractivestorage articles 20, such as for example retail and/or shippingpackages, can be constructed at least in part from a pliable compositestructure 22 having a high degree of pliability and flexibility. Thepliable composite structure 22 has a base layer 24 and a ground calciumcarbonate-containing layer 26 covering the base layer 24, as shown forexample in FIG. 2. The base layer 24 and ground calciumcarbonate-containing layer 26 are shaped, sized and manufactured suchthat the pliable composite structure 22 formed therefrom has apliability that is sufficient to allow for the production of the storagearticles 20. The pliability of the composite structure 22 also impartsan attractive tactile feel to the article 20 that is a substantialimprovement over prior products. The pliable composite structure 22 canbe readily transformed into desired storage article components 33 by atleast one of folding and creasing of the pliable composite structure 22,as well as by using vacuum-forming or thermo-forming techniques.

The pliable composite structure 22 can be formed by controlling thesizes, shapes and manufacture of the ground calcium carbonate-containinglayer 26 and base layer 24 to form the structure 22. For example, athickness of one or more of the layers 26, 24 can be controlled toprovide more or less pliability in the resulting composite structure 22,with thinner layers typically being more pliable than thicker layers.The thicknesses of the layers are also selected with regards to desireddurability requirements, with thicker layers providing more durabilityin some embodiments over very thin layers. A suitable thickness of theground calcium carbonate-containing layer 26 that provides goodpliability as well as durability of the pliable composite structure maybe, for example, from about 2 to about 30 mils.

The manufacture of the layers 26, 24 is also controlled to provide layercompositions that impart the desired pliability in the pliable compositestructure 22. For example, the composition and amount of bonding agentused in the formation of the ground calcium carbonate-containing layer26 can be selected to provide the desired flexibility and pliability ofthe resulting composite structure 22. In one version, a type andprescribed amount of a bonding agent, such as a thermoformable bondingagent, can be added to the ground calcium-containing layer 26 that issufficient to provide a composite structure 22 that is capable of beingformed into a desired package shape by applying at least one of heat,pressure and vacuum, such as for example by at least one ofthermoforming and vacuum forming. Suitable bonding agents that can beincorporated into the ground calcium carbonate-containing materialinclude HPDE, bio-polymers, polylactic acids, and other bonding agents.The calcium carbonate of the ground calcium carbonate-containing layer26 can be derived from a limestone source or other calciumcarbonate-containing sources. The content of the base layer 24 is alsoselected to provide a base layer 24 that is sufficiently flexible foruse in the formation of the pliable composite structure 22, while alsobeing sufficiently durable to allow for at least one of retail andshipping use. The base layer 24 can be formed from materials such aspaperboard, cellulosic fibers, chemical pulps, thermochemical pulps,natural starch-based foams, plastic, paper, felt, non-woven mats, kraftlinerboard and fiberboard, among other materials. The size, shape andcomposition of the layers 26, 24 is selected to provide a pliability ofthe resulting structure 22 that is sufficiently high to allow forformation of storage articles 20 such as at least one of a retailpackage and shipping package that have an attractive look and feel,while still being sufficiently sturdy and durable for at least one ofshipping and retail use.

As known to those of ordinary skill in the art, a “composite” materialis a material comprising two or more substances having differentphysical characteristics, in which each substance retains its identitywhile contributing desirable properties to the whole. The term“composite” may especially refer to those materials for which eachsubstance contributes desirable properties to the whole that are greaterthan the otherwise additive contribution of each substance in theabsence of the other, in effect creating a material that has propertiesgreater than the mere sum of its parts. This is in contrast to, forexample, the prior art non-composite product shown in FIGS. 1 a-1 c, asthe two layers 24, 26 of the pliable composite structure 22 according tothe present invention are bonded along substantially the entireinterface between the layers 24, 26, such as along substantially anentire top surface 25 of the base layer 24, to form a single compositestructure. Also, the characteristics and manufacture of the layers 24,26 and composite structure 22 are selected such that the combinedcomposite structure 22 has properties including pliability andmachinability that go beyond the capabilities of either material aloneand that are not achieved by the prior art product.

The pliable composite structure 22 can be formed using a number ofdifferent manufacturing techniques. For example, a method of forming thecomposite can comprise a milling step in which paperboard or anotherbase layer material is formed into sheets having the desired base layercontent and thickness, and the resulting sheets are gathered onto rolls.The milling step can also include a process of extruding the groundcalcium carbonate material into sheets having the desired chemicalcontent and thickness, and gathering the resulting sheets into rolls.The milling step can further comprise lamination of the base layermaterial with the ground calcium carbonate material to form the pliablecomposite structure 22 having the base layer 24 and ground calciumcarbonate-containing layer 26. The base layer 24 may be laminated withthe ground calcium carbonate-containing layer 26 on one or more surfacesof the layer 24, such as on top and bottom surfaces 25, 27, or on only asingle surface, as show in FIG. 2. The base layer 24 can be laminatedwith the ground calcium carbonate-containing layer 26 by adhering thelayers 24, 26 to one another, for example by applying heat or pressureto one or more of the materials forming the layers 24, 26, or byoptionally applying an adhesive between the layers 24, 26. In oneversion, the pliable composite structure 22 is formed without the use ofadded adhesive between the layers 24, 26.

In one embodiment, the pliable composite structure 22 that is used toform a storage article 20 such as at least one of a retail package 20and shipping package 20 having printing formed on portions thereof, suchas printed advertisements or information about the product containedtherein. For example, the storage article 20 can have printing on one orboth sides of the ground calcium carbonate-containing layer 26 and alsoor alternatively on one or both sides of the base layer 24. The printingcan be carried out by well-known printing techniques, such asflexographic and lithographic printing. Storage articles 20 havingpliable composite structures 22 with ground calcium carbonate-containinglayers 26 can be attractively and brightly printed to increase consumerdemand for the product as well as to convey important information aboutthe product and contents to the customer. In this version, a printingstep comprises feeding the base material or ground calcium-carbonatecontaining material through a printer. The printer can print on one ormultiple surfaces of the material, and the same material can also besent through the same or a subsequent printer.

The base layer material and ground calcium carbonate-containing materialmay also be subjected to a cutting step, either individually or as apart of the combined pliable composite structure, to form parts of thedesired package shape. The cutting step can comprise die-cuttingportions of the materials, or cutting portions of the material orcomposite sheets with a rolling blade, for example. The cutting step canalso form smaller portions for multiple articles.

In further embodiments, the individual materials and/or pliablecomposite structure 22 are formed into a desired shape for the package20 by molding under pressure, heat or vacuum. For example, in a vacuummolding process, the one or more of the material and composite is forcedagainst a mold under the force of vacuum, such that the material orcomposite adopts a shape conforming to the mold. As another example, ina thermoforming process, the materials and/or composite are heated whilepressed against a mold to deform the material until it adopts a desiredshape. Such molding may allow the pliable composite structure 22 toadopt desired shapes, including even rounded or curved shapes. Anexample of a vacuum molding press 60 is shown in FIG. 11, which showstop and bottom press plates 62 a, 62 b and a mold 64, with the pliablecomposite structure 22 being placed between the presses 62 a, 62 b andmold 64 and then vacuum pressed onto the mold by application of a vacuumbetween the presses 62 a, 62 b. The pliability of the structure 22 mayalso allow various folding and creasing steps to be performed to formthe final component shape, without requiring the application of heat orvacuum. A combination of various molding and/or shaping steps may alsobe performed to form the final storage article 20, as well as variouscutting and shaping steps and steps to adhere additional decorative orfunctional parts. Also, one or more pliable composite structures 22 canbe stacked or adhered to one another to form a desired storage articlecomponent 33.

In one version, the pliable composite structure 22 is formed into theshape of a component 33 comprising a box 28 for at least one retail andshipping, as shown for example in FIGS. 3 a-3 b. The box 28 may be inthe form of a cube, rectangular or other box shape that is sized tocontain a retail or shipping product 16. In one version, the box 28 isformed by preparing a pliable composite structure 22 in the form of apliable sheet, for example by performing the milling step describedabove, cutting the structure into the desired shape, and then foldingand/or creasing the sheet, either manually or by machine, to form thefinal three dimensional box shape. In the version shown in FIG. 3 a, thepliable composite structure 22 forms the walls 39 of the box, includingbottom and side walls 39 a, 39 b as well as a fold-over lid portion 39c. The box 28 formed from the pliable composite structure 22 has asmooth and flexible tactile feel that is attractive and pleasing to thetouch, while also being sturdy and durable enough to allow use in retailon store shelves and displays. In one version, the pliability of the box28 is such that it can be readily folded and unfolded into the box shape28, thereby allowing the user to store the box 28 in the unfolded stateand then quickly fold the box into shape when needed for use. The box 28is also desirably sturdy enough to withstand vertical or other stackingof the box 28 with other boxes, such as in pallets for shipping orstorage of products, and may also provide substantial theft deterrence.In one embodiment, the attractive feel of the box 28 as well as theenhanced luster and shine of the box imparted by the groundcalcium-carbonate-containing material makes the box 28 particularlysuitable for the retail of high-end and luxury products where the appealof the overall retail package is important, such as in the retail ofperfumes, cosmetics and jewelry.

In another version, the pliable composite structure 22 is formed intothe shape of a container liner 30 for at least one of retail andshipping use, as shown in FIGS. 4 a and 4 b. The liner 30 is used toline a shipping or retail container 32 to cushion and protect a productbeing held in the container 32, as well as to impart moisture resistanceand deter infiltration of rodents and other pests. In the version shownin FIGS. 4 a and 4 b, the liner 30 formed of the pliable compositestructure 22 that is sufficiently flexible such that it is capable of atleast partially conforming to the shape of the container 32. In theversion shown in FIG. 4 a, the liner 30 is sufficiently flexible toconform to the shape of a rectangular-shaped container 32. In theversion shown in FIG. 4 b, the liner 30 is sufficiently flexible toconform to the shape of a cylindrically-shaped container 32. The liner30 containing the pliable composite structure 22 provides an improvementover for example prior containers formed of unlined corrugated boxes, byreducing dust contamination of the product held therein from thecorrugated material, and also provides moisture, heat, pest and rodentresistance that is an improvement over the prior unlined corrugatedcontainer materials.

In yet another version, the pliable composite structure 22 forms a partof a shipping mailer 34, such as an envelope used to ship documents andother objects through UPS, FEDEX, USPS, etc., as shown in FIG. 5. Thepliable composite structure 22 may be used to form a part of or even allof the mailer structure, excluding sealing parts such as adhesive orattachment brads that seal the mailer opening for shipping, and may befabricated by using a series of folding, creasing and adhesive steps toprepare the desired mailer shape. The pliable composite structure 22 isdesirably sufficiently pliable such that documents and other objects canbe readily accommodated in the mailer 34, while also being sufficientlydurable to resist tearing, snagging and ripping of the shipping mailer34. The shipping mailer 34 formed from the pliable composite structure22 provides numerous advantages over prior mailers 34 not having theimproved composite structure 22. For example, the shipping mailer 34having the pliable composite structure imparts improved moistureresistance while also allowing for highly attractive printing on thepackages, so that instructions regarding the content, shippinginstructions or advertisements can be printed on the mailer. This is incontrast to prior mailers such as paper mailers which are typicallyfabricated to be either water resistant or readily printable, but do nottypically have a highly attractive and readily printable surface that isalso moisture resistant and durable, as is the case for mailers havingthe ground calcium carbonate-containing composite layer.

Other versions of storage articles 20 having the pliable compositestructure 22 include display trays 36 and other sales displays 38, asshow in FIGS. 6 a-6 g. For example, in the embodiments shown in FIGS. 6a and 6 f, the pliable composite structure is cut, shaped and foldedinto the shape of display trays 36 capable of holding and displayingproducts for retail. The trays 36 can have walls and a base sized tohold a desired number of objects, and can also contain cutouts, as shownin FIG. 6 a, or other display arrangement that holds the objects in thetray 36. FIGS. 6 b-6 e and 6 g show embodiments of displays 38 that areeither formed from or contain the pliable composite structure 22 havingthe ground calcium containing material. For example, in the embodimentsshown in FIGS. 6 b-6 d, the pliable composite structure 22 is formed ormolded to form parts of the display 38. The pliable composite structurecan be molded by bending or folded, as well as via thermo orvacuum-forming to form desired parts of the display 38. The embodimentsshown in FIGS. 6 b, 6 d and 6 e show display cases formed from portionsof printed, folded and glued pliable composite structure 22, optionallywith conventionally lithographed parts. The embodiment shown in FIG. 6 cshows a display 38 that has been molded into a desired shape by vacuumforming front and back halves of the display that are formed of thepliable composite structure 22. The pliable composite structure 22 isdesirably sufficiently flexible such that it can be molded with vacuumor thermoforming techniques to form rounded parts 40, such as thoseshown in the embodiment of FIG. 6 c, which may be particularly desirablefor attractive displays 38, as well as in other products. FIG. 6 g showsan embodiment in which the pliable composite structure 22 has been usedto form a display 38 having display trays 36. The display 38 and displaytrays 36 that are formed from or otherwise contain the pliable compositestructure 22 provide highly attractive and moisture resistant displaysand trays, that can be brightly and attractively printed for retail andadvertisement purposes and are highly scuff resistant. The pliablecomposite structure 22 is advantageously shapeable into the desiredretail form, such as by folding or molding of the structure 22, and thusprovides a highly adaptable material for use in improved retaildisplays.

Other uses of the pliable composite structure 22 include its use to formcorrugated structures 42, embodiments of which are shown in FIGS. 7 a-7b, as well as in the formation of slip or tear sheets or protective toppallet covers 44, an embodiment of which is shown in FIG. 8, as aninterior protective packaging component 48, an embodiment of which isshown in FIG. 9, and also molded interior protective packagingcomponents 48, embodiments of which are shown in FIGS. 10 a-10 b. In theembodiment shown in FIGS. 7 a-7 b, corrugated flutes 50 are sandwichedin between top and bottom sheets 52 a, 52 b to form corrugatedstructures 42 suitable for the formation of corrugated boxes and othersimilar applications. One or more of the flutes 50 and sheets 52 a, 52b, may be formed of the pliable composite structure 22, to form acorrugated structure 42 having enhanced pliability as well as moistureand pest resistance. Additionally and/or alternatively, the pliablecomposite structure 22 may contain a ground calcium carbonate-containinglayer 26 that covers a base layer 24 that contains the corrugated partssuch as flutes 50 and top and bottom sheets 52 a, 52 b. For example, asshown in FIG. 7 a, the pliable composite structure 22 may comprise abase layer 24 that is a corrugated material containing flutes 50 andinner top and bottom sheets 51 a, 51 b, with the base layer 24 beingcovered by top and bottom sheets 52 a, 52 b comprising the groundcalcium carbonate-containing layer 26.

In the embodiment shown in FIG. 8, the pliable composite structure 22 isformed into slip sheets or tear sheets 44 for storing or shippingproducts, which sheets 44 can also be scored or folded for use asprotective top pallet covers. As is also shown in FIG. 8, a plurality ofpliable composite sheets 44 can be adhered together to form amulti-layer structure 68, such as a multi-layer tear sheet 44.

In the embodiment shown in FIG. 9, an interior protective packagingcomponent 48 contains upper and lower sheets 54 a, 54 b that are adheredto one another along the periphery 55 of the component, with one or moreof the upper and lower sheets 54 a, 54 b being formed from the pliablecomposite structure 22. The interior protective packaging component 48is filled with shock absorbing material 56 such as EPS, foam, naturalstarch based form, pulp, fiberboard, and the like, to form a componentthat can be placed in packages for shipping or retail to protect theproduct contained in the package.

In the embodiment shown in FIG. 10, the interior protective packagingcomponent 48 comprises a pliable composite structure 22 that is moldedinto a shape suitable for conforming to or otherwise holding andprotecting an object within a shipping package, or to fill voids in apackage, to stabilize and protect fragile items for shipping. Thepliable composite structure 22 may be molded into a desired shape andthen placed overtop of a shock absorbing material 56, such as any ofthose described above. The pliable composite structure 22 used in theseembodiment imparts those advantages as describes above, includingincreased pliability to allow for the formation of the desiredstructures as well as to improve the look and feel of the structure. Thestructure 22 also has improved moisture, theft and pest resistance,while also maintaining good fire and heat resistance. The structure 22further allows high quality printing thereon to allow for userinstructions or advertisements to be printed on the products.

Additional modifications and improvements of the present invention mayalso be apparent to those of ordinary skill in the art. Thus, theparticular combination of components and steps described and illustratedherein is intended to represent only certain embodiments of the presentinvention, and is not intended to serve as limitations of alternativedevices and methods within the spirit and scope of the invention. Alongthese lines, it should be understood that the storage articles 20 havingthe pliable composite structure 22 may take any of a variety of formsthat are known or later developed in the art, and further contemplatesthat existing or newly formed storage articles 20, such as newly formedretail and/or shipping packages, should fall within the scope of thepresent invention. Also, it should be understood that the base layer 24and calcium carbonate-containing layer 26 can comprise various differentmaterials such as other packaging materials and bonding agents that areother than those specifically described.

1. A storage article comprising: a pliable composite structurecomprising; (a) a base layer; and (b) a ground calciumcarbonate-containing layer covering the base layer; wherein the baselayer and ground calcium carbonate-containing layer are shaped, sizedand manufactured such that the pliable composite structure formedtherefrom is sufficiently pliable and flexible to form the storagearticle.
 2. The storage article of claim 1 wherein the pliable compositestructure is formed into the shape of at least one of a retail box andshipping box.
 3. The storage article of claim 2 wherein the pliablecomposite structure is sufficiently pliable to allow for formation ofthe box shape by at least one of folding and creasing of the pliablecomposite structure.
 4. The storage article of claim 1 wherein thepliable composite structure contains a prescribed amount of athermo-formable bonding agent in the ground calcium carbonate-containinglayer that is sufficient to form the storage article shape viathermoforming or vacuum forming.
 5. The storage article of claim 1wherein the base layer is formed from at least one of cellulosic fibers,chemical pulps, thermochemical pulps, natural starch-based foams,plastic, paper, paperboard, felt, non-woven mats, kraft linerboard andfiberboard.
 6. The storage article of claim 1 wherein the ground calciumcarbonate-containing layer is of a thickness in the range of from about2 to about 30 mils.
 7. The storage article of claim 1 wherein thepliable composite structure is in the shape of a shipping mailer.
 8. Thestorage article of claim 1 wherein the pliable composite structure is inthe shape of at least one of a retail box liner and a shipping boxliner.
 9. The storage article of claim 1 wherein the pliable compositestructure is in the shape of at least one of a retail display anddisplay tray.
 10. The storage article of claim 1 wherein the pliablecomposite structure comprises a portion of a corrugated structure. 11.The storage article of claim 1 wherein the pliable composite structurecomprises a portion of a protective interior packaging component.
 12. Amethod of making a component for a storage article, comprising the stepsof: (a) preparing a pliable composite structure by adhering a groundcalcium carbonate-containing layer to a base layer; and (b) shaping thepliable composite structure to form the component for the storagearticle; wherein the ground calcium carbonate-containing layer and baselayer are shaped, sized and manufactured such that the pliable compositestructure formed therefrom is sufficiently pliable and flexible to formthe component for the storage article.
 13. The method according to claim12 wherein the component comprises at least one of a retail box andshipping box, and wherein step (b) comprises shaping the pliablecomposite structure to form the component by at least one of folding andcreasing of the pliable composite structure into a shape correspondingto the at least one retail box and shipping box.
 14. The methodaccording to claim 12 wherein step (a) comprises providing a prescribedamount of a bonding agent in the ground calcium carbonate-containinglayer that is sufficient to allow for vacuum forming or thermo-formingof the pliable composite structure, and step (b) comprises shaping thepliable composite structure into the component by thermo-forming orvacuum-forming of the pliable composite structure.
 15. The methodaccording to claim 12 wherein step (a) comprises preparing a pliablecomposite structure having a ground calcium carbonate-containing layerhaving a thickness of from about 2 to about 30 mils.
 16. A method ofshipping a product or displaying a product for retail, the methodcomprising the steps of: (a) providing a storage article comprising: apliable composite structure comprising; (i) a base layer; and (ii) aground calcium carbonate-containing layer covering the base layer;wherein the base layer and ground calcium carbonate-containing layer areshaped, sized and manufactured such that the pliable composite structureformed therefrom is sufficiently pliable and flexible to form thestorage article; (b) placing the product within the storage article; and(c) shipping the storage article or displaying the storage article forretail.
 17. The method of shipping a product or displaying a product forretail according to claim 16, wherein step (a) comprises providing astorage article comprising a pliable composite structure that is formedinto the shape of at least one of a retail box and shipping box.
 18. Themethod of shipping a product or displaying a product for retailaccording to claim 17, wherein step (a) comprises providing a storagearticle comprising a pliable composite structure that is sufficientlypliable to allow for formation of the box shape by at least one offolding and creasing of the pliable composite structure.
 19. The methodof shipping a product or displaying a product for retail according toclaim 16, wherein step (a) comprises providing a pliable compositestructure containing a prescribed amount of a thermo-formable bondingagent in the ground calcium carbonate-containing layer that issufficient to form the storage article shape via thermoforming or vacuumforming.
 20. The method of shipping a product or displaying a productfor retail according to claim 16, wherein step (a) comprises providing apliable composite structure having a ground calcium carbonate-containinglayer having a thickness of from about 2 to about 30 mils.